CN118181744A - Device for additive manufacturing of three-dimensional objects - Google Patents

Device for additive manufacturing of three-dimensional objects Download PDF

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Publication number
CN118181744A
CN118181744A CN202410461782.2A CN202410461782A CN118181744A CN 118181744 A CN118181744 A CN 118181744A CN 202410461782 A CN202410461782 A CN 202410461782A CN 118181744 A CN118181744 A CN 118181744A
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CN
China
Prior art keywords
energy beam
build material
layer
energy
unit
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202410461782.2A
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Chinese (zh)
Inventor
F·贝希曼
P·舒曼
A·波普
T·伯克斯
M-C·埃伯特
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Concept Laser Co ltd
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Concept Laser Co ltd
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Filing date
Publication date
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Publication of CN118181744A publication Critical patent/CN118181744A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/49—Scanners
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/90—Means for process control, e.g. cameras or sensors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/268—Arrangements for irradiation using laser beams; using electron beams [EB]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/277—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
    • B29C64/282—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] of the same type, e.g. using different energy levels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/364—Process control of energy beam parameters for post-heating, e.g. remelting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Toxicology (AREA)
  • Health & Medical Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • General Health & Medical Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Automation & Control Theory (AREA)
  • Analytical Chemistry (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Powder Metallurgy (AREA)
  • Producing Shaped Articles From Materials (AREA)

Abstract

The invention relates to a device (1) for additive manufacturing of three-dimensional objects by sequentially selectively irradiating and curing layers (2) of powdery building material (3) curable by means of an energy beam (4), the device comprising an irradiation means (8), a detection means (11) and an evaluation means (14), wherein the irradiation means is configured to generate at least a first energy beam (4) and a second energy beam (9), the second energy beam following the path of the first energy beam with defined spatial and/or temporal deviations; the detection device is configured to detect radiation (12) emitted from a portion of the layer (2) of powdered build material (3) selectively irradiated by the first energy beam (4); the evaluation device is configured to evaluate the detected radiation (12) emitted by the portion of the layer (2) of powdered construction material (3) selectively irradiated by the first energy beam (4) in terms of the cooling behavior of said portion.

Description

Device for additive manufacturing of three-dimensional objects
The application is a divisional application of the following application:
filing date of the original application: 2017, 11, 7
Application number of the original application: 201711113076.5
Title of the original application: device for additive manufacturing of three-dimensional objects
Technical Field
The invention relates to a device for additive manufacturing of three-dimensional objects by sequentially and selectively irradiating and curing, layer by layer, layers of powdery building material curable by means of an energy beam.
Background
Corresponding devices for additive manufacturing of three-dimensional objects, such as technical components, are well known and may be implemented, for example, as selective laser sintering devices, selective laser melting devices or selective electron beam melting devices.
It is known that the structural, i.e. in particular mechanical, properties of additively manufactured three-dimensional objects are significantly influenced by the cooling behavior of the selectively solidified parts of the powdered build material layer which are selectively irradiated by the energy beam during the additive manufacturing process. The cooling behavior of the selectively solidified portions of the layer of powdered build material has a significant effect on the structural characteristics of the additively manufactured three-dimensional object because the cooling behavior substantially determines the microstructure of the additively manufactured three-dimensional object. As an example, the cooling behavior may affect the build-up of internal stresses that underlie the formation of (micro) cracks within the additively fabricated three-dimensional object, which may impair the structural properties of the additively fabricated three-dimensional object.
Disclosure of Invention
In view of the above, an object of the present invention is to provide an apparatus for additively manufacturing a three-dimensional object: which allows a reliable and in particular highly integratable determination of the cooling behavior of a layer of powdered build material that has been selectively irradiated by an energy beam during an additive manufacturing process.
This object is achieved by an apparatus for additively manufacturing three-dimensional objects according to claim 1. The claims depending on claim 1 relate to alternative embodiments of the device according to claim 1.
The apparatus described herein is an apparatus for additive manufacturing of three-dimensional objects, such as technical components, by sequentially selectively irradiating and curing layers of a powdered build material ("build material") curable by means of an energy beam layer by layer. The respective build material may include at least one of a metal powder, a ceramic powder, or a polymer powder. The corresponding energy beam may be a laser beam or an electron beam. The corresponding device may be, for example, a selective laser sintering device, a selective laser melting device or a selective electron beam melting device.
The apparatus includes a number of functional devices operable during operation thereof. Each functional device may comprise several functional units. Exemplary functional devices are build material application devices, such as cladding devices, configured to apply a layer of build material to be selectively irradiated and cured, such as in a build plane of a process chamber of an apparatus, and irradiation devices configured to selectively irradiate and cure portions of the layer of build material with at least one energy beam.
The apparatus described herein comprises an illumination device configured to generate at least a first and a second energy beam, wherein the second energy beam follows a path/trajectory of the first energy beam with a defined spatial and/or temporal deviation. The irradiation device is thus configured to selectively irradiate the layer of build material with at least first and second energy beams. Thus, the irradiation device is configured to control the movement of the first and second energy beams in such a way that the second energy beam (directly) follows the path/trajectory of the first energy beam with a defined spatial and/or temporal deviation.
The irradiation device may be configured to generate a first energy beam having different beam characteristics, in particular a higher beam power, a smaller beam size, etc., than the second energy beam.
The first energy beam may have a beam power sufficient to melt, i.e. in particular melt, the build material upon selective irradiation of the build material with the first energy beam. Thus, the energy input to the selectively irradiated portions of the build material layer by the first energy beam is sufficient to melt, in particular melt, the selectively irradiated portions of the build material layer. Thus, the first energy beam is used to melt the build material.
The second energy beam may have a beam power that is insufficient to melt, i.e. in particular melt, the build material when selectively irradiating the build material with the second energy beam. Thus, the energy input to the selectively irradiated portions of the build material layer by the second energy beam is insufficient to selectively melt, i.e., in particular melt, the selectively irradiated portions of the build material layer. However, the energy input by the second energy beam to the selectively irradiated portions of the build material layer is sufficient to temper the portions of the build material layer after being selectively irradiated by the first energy beam. Thus, the second energy beam is used to temper the selectively irradiated portions of the layer of build material. Tempering allows to control the temperature and thus the cooling behaviour of the portions of the layer of building material after being selectively irradiated by the first energy beam.
As will be apparent from the following description of alternative embodiments of the apparatus, the irradiation device may comprise several functional units, for example at least one beam generating unit configured to generate at least one energy beam, i.e. in particular at least a first and a second energy beam, and at least one beam deflecting unit (scanning unit) configured to deflect the energy beam to different positions of the layer of building material.
The apparatus further comprises detection means configured to detect (electromagnetic) radiation emitted or reflected from the portion or a part of the layer of build material selectively illuminated by the first energy beam. The detection device may comprise at least one detection element configured to detect (electromagnetic) radiation emitted or reflected from the portion or a portion of the layer of build material selectively illuminated by the first energy beam. The detection means may be a sensor means, such as an optical or thermal image camera, photodiode, etc., and the detection element may be a sensor element, such as an optical or thermal image camera element, photodiode element, etc.
The apparatus further comprises an evaluation device configured to evaluate the detected radiation emitted from the selectively irradiated portion of the build material layer in relation to the cooling behavior of the respective selectively irradiated portion of the build material layer by the first energy beam. The evaluation is based on the following recognition: the radiation emitted from the portion of the layer of build material selectively irradiated by the first energy beam is a direct or indirect measurement of temperature and, thus, the cooling behaviour of the corresponding portion of the layer of build material selectively irradiated by the first energy beam. The evaluation device may comprise at least one evaluation algorithm configured to evaluate the detected radiation emitted from the portion of the build material layer selectively irradiated by the first energy beam in relation to a cooling behavior of the corresponding portion of the build material layer selectively irradiated by the first energy beam. The evaluation means may be implemented as hardware and/or software.
By detecting radiation emitted or reflected from the portion or portion of the build material layer selectively irradiated by the first energy beam and evaluating the detected radiation emitted from the portion of the build material layer selectively irradiated by the first energy beam in terms of cooling behavior of the corresponding portion of the build material layer selectively irradiated by the first energy beam, an apparatus for additively manufacturing a three-dimensional object is provided: which allows a reliable and in particular highly integratable determination of the cooling behaviour of the selectively solidified portions of the layer of building material that have been selectively irradiated by the energy beam during the additive manufacturing process.
The irradiation device may comprise several functional units allowing the generation of at least a first and a second energy beam, as mentioned above. According to an embodiment, the irradiation device may comprise a first beam generating unit configured to generate a first energy beam and a second beam generating unit configured to generate a second energy beam. According to a further embodiment, the illumination device may comprise only one beam generating unit configured to generate an energy beam (which is split to generate the first and second energy beams) and an associated beam splitting unit configured to split the energy beam generated by the beam generating unit to generate the first and second energy beams. The irradiation apparatus may further comprise at least one beam deflection unit configured to deflect the energy beam to different positions of the layer of build material. The beam deflection unit may comprise several beam deflection elements, such as deflection mirrors, which are in particular movably supported. It is possible that the irradiation device comprises at least a first and a second beam deflection unit, wherein the first beam deflection unit is assigned to the first energy beam for deflecting the first energy beam to a different position of the layer of build material and the second beam deflection unit is assigned to the second energy beam for deflecting the second energy beam to a different position of the layer of build material.
In any case, the illumination device may comprise at least one beam guiding unit configured to guide the first and/or second energy beam along the optical path. The beam guiding unit may comprise several optical elements, such as optical fibers, lenses, mirrors, etc., which construct the optical path. The beam guiding units are typically arranged between the beam generating units and the beam deflecting units to guide the energy beams along optical paths extending from the respective beam generating units to the respective beam deflecting units.
In particular, the irradiation device may comprise a beam guiding unit configured to guide at least the second energy beam, in particular between a beam generating unit configured to generate the second energy beam and a beam deflecting unit configured to deflect at least the second energy beam to a different position of the layer of build material.
The detection means may be assigned to a beam guiding unit configured to guide at least the second energy beam. In particular, the detection means may be arranged in a co-optical axis arrangement (on-axis arrangement) with respect to a beam deflection unit configured to deflect at least the second energy beam. The corresponding on-optical axis arrangement of the detection device allows a highly integrated arrangement of the detection device both in terms of construction and in terms of function. The corresponding on-optical axis arrangement of the detection means also allows to obtain high dynamic and high resolution detection information, such as high dynamic and high resolution detection images, of the detected portion of the corresponding layer of building material. The corresponding co-optical axis arrangement of the detection means also allows to obtain coordinate values etc. of the corresponding detection information.
The beam directing unit may comprise at least one optical element, such as a half mirror element, configured to direct radiation emitted from the portion of the layer of build material selectively illuminated by the first energy beam to the detection device. Thus, the same optical path may be used for both the energy beam and the radiation emitted from the portion of the layer of build material selectively illuminated by the first energy beam. The direction of extension of the radiation emitted from the portion of the building material layer selectively irradiated by the first energy beam through the optical path constructed by the respective beam guiding unit is at least partially the opposite direction of the direction of extension of the energy beam through the optical path.
The evaluation device may be configured to generate evaluation information describing/indicating a cooling behavior of the portion of the build material layer selectively irradiated by the first energy beam, the evaluation information being evaluated from the detected radiation emitted from the portion of the build material layer selectively irradiated by the first energy beam. The evaluation information may describe/indicate various chemical and/or physical parameters directly or indirectly related to the cooling behavior of the portion of the layer of build material selectively irradiated by the first energy beam. Examples of corresponding parameters are combinations of atmosphere, radiation power, temperature, etc. The evaluation information may be transferred to the various functional devices of the apparatus by means of communication links between these functional devices. The assessment information may be communicated to a user interface means of the device, such as a screen, and thereby output to the user.
The apparatus includes control means assigned to and configured to control operation of the various functional means of the apparatus. As an example, the control device may be configured to control the operation of the illumination device. In particular, the control means may be configured to control the operation of the illumination means based on the evaluation information determined by the evaluation means. Thus, by controlling the operation of the illumination means based on the respective evaluation information, the first and/or second energy beam may be controlled in the following manner: i.e. to enable a desired cooling behaviour of the portion of the layer of building material selectively illuminated by the first energy beam and thus a desired microstructure within the object to be additively built. Controlling the operation of the irradiation device and thus the cooling behavior may be implemented in the manner of a control loop to allow real-time control of the cooling behavior and other factors affecting the quality of the additively manufactured object.
The detection device may be configured to additionally detect radiation emitted from a portion of the layer of build material that is currently selectively illuminated by the first energy beam. In this way, not only the cooling behavior of the portion of the build material layer selectively irradiated by the first energy beam can be detected, but also the melting behavior of the portion of the build material layer currently selectively irradiated by the first energy beam can be detected. Of course, the apparatus may also comprise at least one further detection device configured to detect radiation emitted from a portion of the layer of build material that is currently selectively illuminated by the first energy beam.
In any case, the or a further evaluation device may be configured to evaluate the detected radiation emitted from the portion of the build material layer currently being selectively irradiated by the first energy beam in terms of melting behavior of the portion of the build material layer currently being selectively irradiated by the first energy beam. The (further) evaluation means may comprise at least one evaluation algorithm configured to evaluate the detected radiation emitted from the portion of the build material layer currently being selectively irradiated by the first energy beam in terms of melting behavior of the portion of the build material layer currently being selectively irradiated by the first energy beam. The evaluation means may be implemented as hardware and/or software.
The invention also relates to an evaluation device for a device as described above. The evaluation device is configured to evaluate at least the detected radiation emitted from the selectively irradiated portion of the build material layer with respect to a cooling behavior of the selectively irradiated portion of the build material layer with the first energy beam, which is generated by the irradiation device of the apparatus. The description of the device applies in a similar manner to the evaluation device.
The invention further relates to a method for additive manufacturing of a three-dimensional object by sequentially and selectively irradiating and curing layers of build material curable by means of an energy beam layer by layer. The method comprises the following steps: generating at least two energy beams, wherein the second energy beam follows the path of the first energy beam with a defined spatial and/or temporal deviation; detecting radiation emitted from portions of the layer of build material selectively irradiated by the first energy beam; and evaluating the detected radiation emitted from the portion of the build material layer selectively irradiated by the first energy beam in terms of cooling behavior of the portion of the build material layer selectively irradiated by the first energy beam. The method may be implemented as, for example, a selective laser sintering method, a selective laser melting method, or a selective electron beam melting method. The description of the apparatus applies in a similar manner to this method.
Drawings
Exemplary embodiments of the present invention will be described with reference to the accompanying drawings, in which a single figure 1 shows a schematic diagram of a section of an apparatus for additive manufacturing of three-dimensional objects according to an exemplary embodiment.
Detailed Description
Fig. 1 shows a schematic diagram of a section of a device 1 for additive manufacturing of three-dimensional objects (e.g. technical components) by sequentially selectively irradiating and subsequently solidifying layers 2 layer by layer, the layers 2 being composed of a powdered build material 3 (e.g. metal powder) which is curable by means of an energy beam 4 (e.g. a laser beam). The apparatus 1 may be, for example, a selective laser melting apparatus.
The device 1 comprises several functional means operable during its operation. Each functional device may comprise several functional units. The device 1 comprises control means 23, the control means 23 being assigned to the respective functional means of the device 1 and being configured to control the operation of these functional means.
Exemplary functional means are a build material application means 5, for example a cladding means, configured to apply a layer 2 of build material 3 to be selectively irradiated and cured in a build plane E of a process chamber 7 of the apparatus 1, and an irradiation means 8 configured to selectively irradiate and cure portions of the layer 2 of build material 3 with at least one energy beam 4.
The irradiation device 8 is configured to generate at least a first energy beam 4 and a second energy beam 9, wherein the second energy beam 9 follows the path/trajectory of the first energy beam 4 with a defined deviation delta. The irradiation device 8 is thus configured to selectively irradiate the layer 2 of building material 3 with at least the first and second energy beams 4, 9. The irradiation device 8 is thus configured to control the movement of the first and second energy beams 4, 9 in such a way that the second energy beam 9 follows (directly) the path/trajectory (indicated by arrow 0) of the first 1 energy beam 4 with a defined spatial deviation delta.
The irradiation device 8 is configured to generate a first energy beam 4 having different beam characteristics than a second energy beam 9. The first energy beam 4 has a beam power that is sufficient to melt, i.e. in particular melt, the build material 3 when the build material 3 is selectively irradiated with the first energy beam 4. The energy input by the first energy beam 4 to the selectively irradiated portions of the layer 2 of building material 3 is thus sufficient to melt, in particular melt, the building material 3. Thus, the first energy beam 4 is used to melt the build material 3.
The second energy beam 9 has a beam power which is insufficient to melt, i.e. in particular melt, the build material 3 when the build material 3 is selectively irradiated with the second energy beam 9. Thus, the energy input by the second energy beam 9 to the selectively irradiated portions of the layer 2 of build material 3 is insufficient to melt, i.e. in particular melt, the build material 3. However, the energy input by the second energy beam 9 to the selectively irradiated portions of the layer 2 of build material 3 is sufficient to temper the portions of the layer 2 of build material 3 after being selectively irradiated by the first energy beam 4. Thus, the second energy beam 9 is used to temper the build material 3. Tempering allows to control the temperature and thus the cooling behaviour of the corresponding portion of the layer 2 of building material 3 after being selectively irradiated by the first energy beam 4.
The apparatus 1 further comprises detection means 11, the detection means 11 being configured to detect (electromagnetic) radiation 12 emitted or reflected from a portion of the layer 2 constituted by the build material 3 selectively irradiated by the first energy beam 4. The detection device 11 comprises at least one detection element 13, the detection element 13 being configured to detect (electromagnetic) radiation emitted or reflected from a portion of the layer 2 constituted by the build material 3 selectively illuminated by the first energy beam 4. The detection means 11 may be a sensor means, such as an optical or thermal image camera, photodiode, etc., and the detection element 13 may be a sensor element, such as an optical or thermal image camera element, photodiode, etc.
The apparatus 1 further comprises evaluation means 14, the evaluation means 14 being configured to evaluate the detected radiation 12 in terms of a cooling behavior of a respective portion of the layer 2 of the build material 3 selectively irradiated by the first energy beam 4. The evaluation is based on the following recognition: the radiation 12 emitted from the portion of the layer 2 composed of the build material 3 selectively irradiated by the first energy beam 4 is a direct or indirect measurement of the temperature and thus of the cooling behaviour of the corresponding portion of the layer 2 composed of the build material 3 selectively irradiated by the first energy beam 4. The evaluation device 14 may comprise at least one evaluation algorithm configured to evaluate the detected radiation 12.
The evaluation device 14 is configured to generate evaluation information describing/indicating a cooling behavior of the portion of the layer 2 of the build material 3 selectively irradiated by the first energy beam 4, which evaluation information is evaluated on the basis of the detected radiation 12 emitted from the portion of the layer 2 of the build material 3 selectively irradiated by the first energy beam 4. The evaluation information may describe/indicate various chemical and/or physical parameters directly or indirectly related to the cooling behavior of the portion of the layer 2 constituted by the build material 3 selectively irradiated by the first energy beam 4. The evaluation information can be transferred to the various functional devices of the apparatus 1 by means of communication links between these functional devices. The assessment information may be communicated to a user interface means 22, such as a screen, of the device 1 and thereby output to the user.
The control means 23 may be configured to control the operation of the illumination means 8 based on the evaluation information determined by the evaluation means 14. Thus, by controlling the operation of the illumination means 8 based on the respective evaluation information, the first and/or second energy beams 4, 9 may be controlled in the following manner: that is, it is enabled to achieve a desired cooling behavior of the portion of the layer 2 composed of the build material 3 selectively irradiated by the first energy beam 4 and thereby a desired microstructure within the three-dimensional object to be additively built. Controlling the operation of the irradiation device 8 and thus the cooling behaviour may be implemented in the manner of a control loop to allow real-time control of the cooling behaviour and other factors affecting the quality of the additively manufactured object.
By detecting radiation 12 emitted or reflected from the portions of the layer 2 composed of the build material 3 that are selectively irradiated by the first energy beam 4 and evaluating the detected radiation 12 in terms of the cooling behavior of the respective portions of the layer 2 composed of the build material 3 that are selectively irradiated by the first energy beam 4, the apparatus 1 allows a reliable and in particular highly integrated determination of the cooling behavior of the respective selectively solidified portions of the layer 2 composed of the build material 3 that have been selectively irradiated during the additive manufacturing process.
According to the exemplary embodiment given in fig. 1, the illumination device 8 comprises a first beam generating unit 15 configured to generate the first energy beam 4 and a second beam generating unit 16 configured to generate the second energy beam 9. However, the irradiation device 8 may also comprise only one beam generating unit configured to generate an energy beam (which is split to generate the first and second energy beams) and an associated beam splitting unit (not shown) configured to split the energy beam generated by the beam generating unit to generate the first and second energy beams 4, 9.
According to the exemplary embodiment given in fig. 1, the irradiation device 8 comprises a first beam deflection unit 17 and a second beam deflection unit 18, wherein the first beam deflection unit 17 is assigned to the first energy beam 4 for deflecting the first energy beam 4 to different positions of the layer 2 of build material 3 and the second beam deflection unit 18 is assigned to the second energy beam 9 for deflecting the second energy beam 9 to different positions of the layer 2 of build material 3. Each beam deflection unit 17, 18 comprises a number of beam deflection elements (not shown), such as deflection mirrors, which are in particular movably supported.
The irradiation device 8 further comprises two beam guiding units 19, 20, wherein the first beam guiding unit 19 is configured to guide the first energy beam 4 along an optical path extending from the first beam generating unit 15 to the first beam deflecting unit 17, and the second beam guiding unit 20 is configured to guide the second energy beam 9 along an optical path extending from the second beam generating unit 16 to the second beam deflecting unit 18.
As can be seen in fig. 1, the detection means 11 are assigned to a second beam guiding unit 20. In particular, the detection device 11 is arranged in a co-optical axis arrangement with respect to the second beam deflection unit 18. The corresponding on-optical axis arrangement of the detection device 11 allows a highly integrated arrangement of the detection device 11 both in terms of construction and in terms of function. The corresponding homooptical axis arrangement of the detection means 11 also allows to obtain corresponding high-dynamic and high-resolution detection information, such as high-dynamic and high-resolution detection images, of the detected portion of the layer 2 constituted by the build material 3. The corresponding co-optical axis arrangement of the detection means 11 also allows to obtain coordinate values etc. of the corresponding detection information.
The second beam guiding unit 18 may comprise at least one optical element 21, e.g. a half mirror element, configured to guide radiation 12 emitted from the portion of the layer 2 constituted by the build material 3 selectively irradiated by the first energy beam 4 to the detection device 11. Thus, the same optical path may be used for both the energy beam 9 and the radiation 12 emitted from the portion of the layer 2 constituted by the build material 3 selectively irradiated by the first energy beam 4. The direction of extension of the radiation 12 emitted from the part of the layer 2 constituted by the build material 3 through the optical path constituted by the second beam guiding unit 18 is at least partially the opposite direction to the direction of extension of the energy beam 9 through the optical path.
The detection device 11 or a further detection device (not shown) may be configured to additionally detect radiation emitted from the portion of the layer 2 composed of the build material 3 that is currently selectively irradiated by the first energy beam 4. In this way, it is possible to detect not only the cooling behavior of the portion of the layer 2 composed of the build material 3 that has been selectively irradiated by the first energy beam 4, but also the melting behavior of the portion of the layer 2 composed of the build material 3 that is currently selectively irradiated by the first energy beam 4.
In any case, the evaluation device 14 or a further evaluation device may be configured to evaluate the detected radiation emitted from the portion of the layer 2 of the build material 3 that is currently selectively irradiated by the first energy beam 4 in terms of the melting behavior of the portion of the layer 2 of the build material 3 that is currently selectively irradiated by the first energy beam 4. The (further) evaluation means 14 may comprise at least one evaluation algorithm configured to evaluate the detected radiation emitted from the portion of the layer 2 of build material 3 that is currently selectively irradiated by the first energy beam 4 in terms of the melting behavior of the portion of the layer 2 of build material 3 that is currently selectively irradiated by the first energy beam 4.
The apparatus 1 is configured to implement a method for additive manufacturing of a three-dimensional object by sequentially selectively irradiating and curing layers 2 of build material 3 curable by means of an energy beam 4 layer by layer. The method comprises the following steps: generating at least two energy beams 4, 9, wherein the second energy beam 9 follows the path of the first energy beam 4 with a defined deviation; detecting radiation 12 emitted from the portion of the layer 2 constituted by the build material 3 selectively irradiated by the first energy beam 4; and evaluating the detected radiation 12 emitted from the portion of the layer 2 of build material 3 selectively irradiated by the first energy beam 4 in terms of cooling behavior of the portion of the layer 2 of build material 3 selectively irradiated by the first energy beam 4.

Claims (6)

1. An apparatus (1) for additive manufacturing of a three-dimensional object by sequentially selectively irradiating and curing layers (2) of a powdered build material (3) curable by means of an energy beam (4), layer by layer, the apparatus (1) comprising:
-an irradiation device (8), the irradiation device (8) being configured to generate at least a first energy beam (4) and a second energy beam (9), wherein the first energy beam (4) has a beam power sufficient to melt the build material when the build material is selectively irradiated with the first energy beam (4), the second energy beam (9) follows the path of the first energy beam (4) with a defined spatial and/or temporal deviation, and the second energy beam (9) has a beam power insufficient to melt the build material when the build material is selectively irradiated with the second energy beam (9), wherein the irradiation device (8) comprises:
A first beam generating unit (15) configured to generate a first energy beam (4) and a second beam generating unit (16) configured to generate a second energy beam (9);
A first beam deflection unit (17) and a second beam deflection unit (18), the first beam deflection unit (17) being assigned to the first energy beam (4) for deflecting the first energy beam (4) to different positions of the layer (2) of build material (3), the second beam deflection unit (18) being assigned to the second energy beam (9) for deflecting the second energy beam (9) to different positions of the layer (2) of build material (3); and
A first beam guiding unit (19) and a second beam guiding unit (20), the first beam guiding unit (19) being configured to guide the first energy beam (4) along a first optical path extending from the first beam generating unit (15) to the first beam deflecting unit (17), the second beam guiding unit (20) being configured to guide the second energy beam (9) along a second optical path extending from the second beam generating unit (16) to the second beam deflecting unit (18);
-a detection device (11), the detection device (11) being configured to detect radiation (12) emitted from a portion of a layer (2) of powdered build material (3) selectively irradiated by a first energy beam (4), wherein the radiation emitted from the portion of the layer (2) travels at least partially in an opposite direction along the second optical path and is directed by the second beam deflection unit (18) to the detection device (11), wherein the detection device (11) is assigned to the second beam guiding unit (20) and the detection device (11) is arranged in a co-optical axis arrangement with respect to the second beam deflection unit (18);
-an evaluation device (14), the evaluation device (14) being configured to evaluate the detected radiation (12) emitted from the portion of the layer (2) of powdered build material (3) selectively irradiated by the first energy beam (4) in terms of a cooling behavior of the portion of the layer (2) of powdered build material (3) selectively irradiated by the first energy beam (4).
2. The apparatus according to claim 1, wherein the second beam guiding unit (20) comprises at least one optical element (21), such as a half mirror element, configured to guide radiation (12) emitted from a portion of the layer (2) of powdered build material (3) selectively irradiated by the first energy beam (4) to the detection device (11).
3. Apparatus according to any one of the preceding claims, wherein the evaluation device (14) is configured to generate evaluation information indicative of a cooling behavior of the portion of the layer (2) of powdered build material (3) selectively irradiated by the first energy beam (4) evaluated from the detected radiation (12) emitted from the portion of the layer (2) of powdered build material (3) selectively irradiated by the first energy beam (4).
4. A device according to claim 3, wherein it further comprises control means (23) configured to control the operation of the illumination means (8), the control means (23) being configured to control the operation of the illumination means (8) based on evaluation information determined by the evaluation means (14).
5. The apparatus according to any one of the preceding claims, wherein the detection device (11) or at least one further detection device is configured to detect radiation emitted from a portion of the layer (2) of powdered build material (3) that is currently selectively irradiated by the first energy beam (4).
6. A method for additive manufacturing of a three-dimensional object by sequentially selectively irradiating and curing layers (2) of powdered build material (3) curable by means of an energy beam (4) layer by layer, the method comprising the steps of:
-generating at least two energy beams (4, 9) via an irradiation device (8), wherein a first energy beam (4) has a beam power sufficient to melt the build material when the build material is selectively irradiated with the first energy beam (4), a second energy beam (9) follows the path of the first energy beam (4) with a defined spatial and/or temporal deviation, and the second energy beam (9) has a beam power insufficient to melt the build material when the build material is selectively irradiated with the second energy beam (9), wherein the irradiation device (8) comprises:
A first beam generating unit (15) configured to generate a first energy beam (4) and a second beam generating unit (16) configured to generate a second energy beam (9);
A first beam deflection unit (17) and a second beam deflection unit (18), the first beam deflection unit (17) being assigned to the first energy beam (4) for deflecting the first energy beam (4) to different positions of the layer (2) of build material (3), the second beam deflection unit (18) being assigned to the second energy beam (9) for deflecting the second energy beam (9) to different positions of the layer (2) of build material (3); and
A first beam guiding unit (19) and a second beam guiding unit (20), the first beam guiding unit (19) being configured to guide the first energy beam (4) along a first optical path extending from the first beam generating unit (15) to the first beam deflecting unit (17), the second beam guiding unit (20) being configured to guide the second energy beam (9) along a second optical path extending from the second beam generating unit (16) to the second beam deflecting unit (18);
-detecting radiation (12) emitted from a portion of a layer (2) constituted by a powdered build material (3) selectively illuminated by a first energy beam (4) via a detection device (11) assigned to the second beam guiding unit (20) and the detection device (11) being arranged in a co-optical axis arrangement with respect to the second beam deflecting unit (18), wherein the radiation emitted from the portion of the layer (2) travels at least partially in an opposite direction along the second optical path and is guided by the second beam deflecting unit (18) to the detection device (11);
-evaluating the detected radiation (12) emitted from the portion of the layer (2) of powdered build material (3) selectively irradiated by the first energy beam (4) in terms of cooling behavior of the portion of the layer (2) of powdered build material (3) selectively irradiated by the first energy beam (4).
CN202410461782.2A 2017-08-16 2017-11-07 Device for additive manufacturing of three-dimensional objects Pending CN118181744A (en)

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